Miller Thunderbolt 225 Owner's Manual

AC/DC, 300/200 AC/DC, 225, And 300ProcessesDescriptionArc Welding Power SourceOM-316 087 083PDecember 2003Thunderbolt XLRStick (SMAW) Welding225 And 3

OM-316 Page 6Revenez à la table des matièresLe rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) sus

OM-316 Page 7Revenez à la table des matières2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien del’appareil.Risque D’I

OM-316 Page 8Revenez à la table des matières2-4. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de l

OM-316 Page 9Return To Table Of ContentsSECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsAAmperes Single PhaseSingle PhaseTransformerSingle PhaseTra

OM-316 Page 10Return To Table Of ContentsSECTION 4 − INSTALLATION4-1. SpecificationsAC/DC ModelsModeRated WeldingOutputAmperageRangeMaximumOpen-Circui

OM-316 Page 11Return To Table Of Contents4-2. Duty Cycle ChartsA. For AC/DC Models2 Minutes Welding 8 Minutes RestingSB-086 727 / SB-099 602-ADuty Cyc

OM-316 Page 12Return To Table Of Contents4-3. Volt-Ampere CurvesA. For AC/DC Models193 509 / 193 510 / 193 511 / 193 512The volt-ampere curves show th

OM-316 Page 13Return To Table Of ContentsB. For AC Models193 508 / 193 513 / 193 511The volt-ampere curves show theminimum and maximum voltageand ampe

OM-316 Page 14Return To Table Of Contents4-4. Selecting A LocationRef. ST-151 556 / ST-217 855-A1 Rating Label (See Section3-2)Locate unit near corre

OM-316 Page 15Return To Table Of Contents4-5. Installing Electrode Holder And Work ClampST-802 251 / ST802 105-CY Turn Off unit and disconnectinput po

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-316 Page 16Return To Table Of Contents4-7. Electrical Service GuideInput Voltage115 220 230 400 460Input Amperes At Rated Output95 [70]47.5[67][39]

OM-316 Page 17Return To Table Of Contents4-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DC Models From 115 VoltsFollow a

OM-316 Page 18Return To Table Of Contents4-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300Amperes AC Models From 230

OM-316 Page 19Return To Table Of Contents4-10. Connecting Input PowerST-802 246Y Disconnect and lockout/tag-out input power before con-necting input c

OM-316 Page 20Return To Table Of ContentsSECTION 5 − OPERATION5-1. ControlsA. Controls For AC/DC ModelsRef. ST-190 600-B / ST-802 105-C1 Amperage Adju

OM-316 Page 21Return To Table Of ContentsB. Controls For AC ModelsRef. ST-190 599-A / ST-802 105-C1 Amperage Adjustment Control2 Power Switch3 Mode Sw

OM-316 Page 22Return To Table Of ContentsSECTION 6 − MAINTENANCE & TROUBLESHOOTING6-1. Routine MaintenanceY Disconnect power before maintaining.3

OM-316 Page 23Return To Table Of Contents6-3. Reinstalling Amperage Adjustment IndicatorST-802 248-CY Turn Off welding powersource and disconnect inpu

OM-316 Page 24Return To Table Of Contents6-4. TroubleshootingTrouble RemedyNo weld output; fan does not run. Be sure line disconnect switch is in On p

OM-316 Page 25Return To Table Of ContentsSECTION 7 − ELECTRICAL DIAGRAMSSA-191 364Figure 7-1. Circuit Diagram For AC/DC (230 Volts) ModelsSA-191 365Fi

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-316 Page 26Return To Table Of ContentsSA-191 363-ASECT1S2WORK ELECTRODERZ1SR1CONNECTED FOR 230 VOLTSPRIGRNS11 23 4CONNECTED FOR 115 VOLTSPRIT11234P

OM-316 Page 27Return To Table Of ContentsSA-191 369SECS2WORK ELECTRODERZ1SR1CONNECTED FOR 400 VOLTSPRIT1GRNS1230V1234 4CONNECTED FOR 230 VOLTSPRIT1132

OM-316 Page 28Return To Table Of ContentsSA-191 362WORK230PRISECT1GRNVOLTONLYS2AC HIGHAC LOWELECTRODEPLG1FMS1Figure 7-7. Circuit Diagram For 225 (230

OM-316 Page 29Return To Table Of ContentsWORK220PRISECT1S.O.P.GRNVOLTONLYS2AC HIGHAC LOWELECTRODEPOWERCORDFMS1SA-191 366Figure 7-9. Circuit Diagram Fo

OM-316 Page 30Return To Table Of ContentsSECTION 8 − WELDING METHODS & TROUBLESHOOTINGmod5.1* 9/92A. Welding Methods8-1. Shielded Metal Arc Weldin

OM-316 Page 31Return To Table Of Contents8-2. Electrode And Amperage Selection ChartRef. ST-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/32

OM-316 Page 32Return To Table Of Contents8-3. Striking An ArcS-0049 / S-00501 Electrode2 Workpiece3 ArcDrag electrode across workpiecelike striking a

OM-316 Page 33Return To Table Of Contents8-5. Weld Bead CharacteristicsRef. S-0052-B1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater During

OM-316 Page 34Return To Table Of Contents8-7. Electrode Movement During WeldingS-0054-A1 Stringer Bead − Steady Move-ment Along Seam2 Weave Bead − Sid

OM-316 Page 35Return To Table Of Contents8-9. Lap JointsS-0063 / S-00641 Electrode2 Single-Layer Fillet WeldMove electrode in circular motion.3 Multi-

OM-316 Page 36Return To Table Of ContentsTable 6-2. Excessive SpatterExcessive Spatter − scattering of moltenmetal particles that cool to solid form n

OM-316 Page 37Return To Table Of ContentsTable 6-5. Excessive PenetrationGood PenetrationExcessive Penetration − weld metal melt-ing through base meta

OM-316 Page 38Return To Table Of ContentsSECTION 9 − PARTS LISTSA-802 245-E. Hardware is common andnot available unless listed.31Figure 9-1. Main Asse

OM-316 Page 39Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main AssemblyQuantity1 134 464 LABEL, warning general precautio

OM-316 Page 40Return To Table Of ContentsNotes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 8/03Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-316 Page 1Return To Table Of ContentsSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/031-1. Symbol UsageMeans Warning! Watch Out! There ar

OM-316 Page 2Return To Table Of ContentsArc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can

OM-316 Page 3Return To Table Of Contents1-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install

OM-316 Page 4Return To Table Of Contents1-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Amer

OM-316 Page 5Revenez à la table des matièresSECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANTUTILISATIONsom_fre 8/032-1. Signification des symbolesSign